Semiconductor device that facilitates a reduction in the occurrences of cracking in a semiconductor layer accompanying thermal stress

ABSTRACT

An emitter electrode includes a first electrode layer, a second electrode layer, and a third electrode layer. The first to third electrode layers are laid in this order on an emitter layer. A solder layer is further laid on the third electrode layer. The first electrode layer covers the emitter layer and a gate oxide film in a front surface of a semiconductor chip. A first electroconductive material forming the first electrode layer has AlSi as its main component. A second electroconductive material forming the second electrode layer has a linear expansion coefficient different from that of the first electroconductive material and is lower in mechanical strength than the first electroconductive material. A third electroconductive material constituting the third electrode layer has a linear expansion coefficient different from that of the first electroconductive material and has solder wettability higher than that of the first electrode layer.

BACKGROUND

Technical Field

The present application relates to a semiconductor device.

Background Art

Power semiconductor devices such as IGBTs and power MOSFETs have beenstudied and developed, for example, as disclosed in Japanese PatentLaid-Open No. 2007-5368. The semiconductor device disclosed in thispublication has an AlSi layer, an Ni layer and a solder layer laid oneon another in this order on a semiconductor substrate formed, forexample, of silicon. For provision of the semiconductor layer, an Nilayer having good solder wettability is required. An Al-based layer suchas an AlSi layer is provided for performing Ni plating. The need for anAl-based layer is specifically mentioned, for example, in paragraph 0007in this publication.

In a power semiconductor element with which electric power is handled,the amount of heat generation accompanying its operation is large and anelectrode laid on a front surface of a semiconductor layer is thermallyexpanded by heat generation. When a stress is caused in the electrodeand the stack structure of the semiconductor layer with a change intemperature, there is a risk of a crack being generated in thesemiconductor layer surface or the electrode. Also in an electrodehaving a stack of layers of different metals having different linearexpansion coefficients as in the above-mentioned related art, stress isalso caused between the layers by thermal expansion. However, theabove-mentioned publication lacks consideration of the problem ofcracking accompanying such thermal stress. With conventionalsemiconductor devices, there have been problems to be solved from theviewpoint of thermal stress.

SUMMARY

In view of the above-described problems, an object of the presentinvention is to provide a semiconductor device in which the occurrenceof cracking in a semiconductor layer accompanying thermal stress isreduced.

According to one aspect of the present invention, a semiconductor deviceincludes: a semiconductor layer; a first electrode layer provided on afront surface of the semiconductor layer and formed of a firstelectroconductive material; a second electrode layer laid on the firstelectrode layer; and a third electrode layer laid on the secondelectrode layer. The second electrode layer is formed of a secondelectroconductive material having a linear expansion coefficientdifferent from that of the first electroconductive material and lower inmechanical strength than the first electroconductive material. The thirdelectrode layer is formed of a third electroconductive material having alinear expansion coefficient different from that of the firstelectroconductive material and having solder wettability higher thanthat of the first electroconductive material.

According to another aspect of the present invention, a semiconductordevice includes: a semiconductor layer; a first electrode layer laid ona front surface of the semiconductor layer and formed of AlCu or AlSiCu;and a second electrode layer laid on the first electrode layer andformed of Cu.

Other and further objects, features and advantages of the invention willappear more fully from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view showing a power semiconductor moduleaccording to a first embodiment of the present invention;

FIG. 2 is a schematic sectional view of the power semiconductor moduleaccording to the first embodiment of the present invention;

FIG. 3 is a schematic plan view of the semiconductor device according tothe first embodiment of the present invention;

FIG. 4 is a schematic sectional view of the semiconductor deviceaccording to the first embodiment of the present invention;

FIG. 5 is a schematic plan view of the other semiconductor deviceaccording to the first embodiment of the present invention;

FIG. 6 is a schematic sectional view of the other semiconductor deviceaccording to the first embodiment of the present invention;

FIG. 7 is a schematic sectional view of a semiconductor device accordingto a modified example of the first embodiment of the present invention;

FIG. 8 is a schematic sectional view of a semiconductor device accordingto another modified example of the first embodiment of the presentinvention;

FIG. 9 is a schematic plan view of a semiconductor device according tothe second embodiment of the present invention;

FIG. 10 is a schematic sectional view of the semiconductor deviceaccording to the second embodiment of the present invention;

FIG. 11 is a schematic plan view of a semiconductor device according toa modified example of the second embodiment of the present invention;

FIG. 12 is a schematic sectional view of the other semiconductor deviceaccording to a modified example of the second embodiment of the presentinvention;

FIG. 13 is a schematic sectional view of a semiconductor deviceaccording to another modified example of the second embodiment of thepresent invention;

FIG. 14 is a schematic sectional view of a semiconductor deviceaccording to a further modified example of the embodiment of the presentinvention;

FIG. 15 is a schematic sectional view of a semiconductor deviceaccording to a further modified example of the embodiment of the presentinvention;

FIG. 16 is a schematic sectional view of a semiconductor deviceaccording to a further modified example of the embodiment of the presentinvention;

FIG. 17 is a schematic sectional view of a semiconductor deviceaccording to a further modified example of the embodiment of the presentinvention; and

FIG. 18 is a schematic sectional view of a semiconductor deviceaccording to a further modified example of the embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment

FIG. 1 is a schematic plan view showing a power semiconductor module 10according to a first embodiment of the present invention. FIG. 1illustrates an internal structure of the power semiconductor module 10seen through a molding resin 40. FIG. 2 is a schematic sectional view ofthe power semiconductor module 10. FIG. 2 shows a section of the powersemiconductor module 10 taken along line A-A in FIG. 1.

The power semiconductor module 10 includes a heat radiating plate 20, asemiconductor device 100 and a semiconductor device 150 provided on theheat radiating plate 20, a lead frame 12 soldered on the semiconductordevice 100 and the semiconductor device 150, a lead frame 14 connectedto a gate electrode pad 142 on the semiconductor device 100 by wires 16,and the molding resin 40 that covers these components while exposing endportions of the lead frames 12 and 14. In the first embodiment, thesemiconductor device 100 is, for example, an insulated gate bipolartransistor (IGBT) while the semiconductor device 150 is, for example, adiode. The heat radiating plate 20 is formed, for example, by providingan insulating layer 22 and an electrode pattern 21 on a metal plate 23.The electrode pattern 21 is soldered to the semiconductor devices 100and 150. A back surface (collector) of the semiconductor device 100 isconnected to the electrode pattern 21, though this connection is notshown in FIGS. 1 and 2. Another lead frame connected to the electrodepattern 21 by wires or the like may be further provided. The structureof the power semiconductor module 10 schematically shown in FIGS. 1 and2 is only an example. Modifications, for example, in terms of thenumbers of semiconductor devices 100 and 150, electrical connections forthe semiconductor devices 100 and 150 and the positions and the numberof lead frames according to various well-known device forms can be made.The power semiconductor module 10 according to the first embodiment isof a transfer mold package structure covered with the molding resin 40.However, the present invention is not limited to this. The presentinvention may be a power semiconductor module having the semiconductordevices 100 and 150 housed in a resin case together with an insulatedcircuit substrate and including terminals protecting out of the case.Junctions between the semiconductor devices 100 and 150 and the leadframe 12 are made by means of a solder layer 130, while junctionsbetween the semiconductor devices 100 and 150 and the heat radiatingplate 20 are made by means of solder 30.

FIG. 3 is a schematic plan view of the semiconductor device 100according to the first embodiment of the present invention. FIG. 4 is aschematic sectional view of the semiconductor device 100, and shows asection of the semiconductor device 100 taken along line B-B in FIG. 3.The semiconductor device 100 is an IGBT having a trench gate electrode104. The semiconductor device 100 includes a semiconductor chip 102, agate electrode pad 142 and an emitter electrode 120 provided on asurface of the semiconductor chip 102, and a collector electrode 140provided on a back surface of the semiconductor chip 102. While thefirst embodiment is described by way of example with respect to a casewhere a semiconductor substrate material constituting the semiconductorchip 102 is silicon carbide (SiC), Si or a wide-bandgap semiconductorother than SiC may alternatively be used as described later.

The semiconductor chip 102 includes an n⁻-type drift layer 103 formed ofSiC, an n⁺-type charge accumulation layer 107 laid above the drift layer103, a p-type base layer 108 laid above the charge accumulation layer107, trench gate electrodes 104 formed of polysilicon and reaching thedrift layer 103 by extending through the p-type base layer 108 and thecharge accumulation layer 107 with a gate insulating film 105 interposedbetween the trench gate electrode 104 and these layers, an n⁺-typeemitter layer 106 provided on opposite sides of each trench gateelectrode 104 with the gate insulating film 105 interposed therebetween,and a gate oxide film 109 provided above each trench gate electrode 104.An emitter electrode 120 is provided so as to cover the gate oxide film109 and the emitter layer 106. The semiconductor chip 102 also includes,as its portions on the back surface side, an n⁺-type buffer layer 110laid below the drift layer 103, and a p⁺-type collector layer 111provided below the buffer layer 110. The collector electrode 140 isprovided on a back surface of the collector layer 111.

A guard ring 112 is provided outside a region in the semiconductor chip102 where the trench gate electrode 104, the emitter layer 106 and otherportions of the semiconductor chip 102 are formed (i.e., the cellregion). A channel stopper 113 is further provided outside the guardring 112. The channel stopper 113 and the guard ring 112 are notelectrically connected with the emitter layer 106. The collectorelectrode 140 provided on the back surface of the semiconductor chip 102covers almost the whole of the back surface of the semiconductor chip102. The emitter electrode 120 is formed so as to be a size smaller thanthe collector electrode 140 as seen in the plan view of thesemiconductor chip 102.

While the charge accumulation layer 107 is provided in one preferredmode according to the present embodiment, an IGBT not having the chargeaccumulation layer 107 may suffice.

The emitter electrode 120 includes a first electrode layer 121, a secondelectrode layer 122 and a third electrode layer 123. The first electrodelayer 121, the second electrode layer 122 and the third electrode layer123 are laid one on another on the emitter layer 106 in this order. Thesolder layer 130 is further laid on the third electrode layer 123. Asshown in FIG. 2, the third electrode layer 123 is soldered to the leadframe 12 by means of the solder layer 130. The guard ring 112 isprovided so as to surround the first electrode layer 121 as seen in theplan view of the semiconductor chip 102 shown in FIG. 3. Further, in apreferred mode according to the first embodiment, the second electrodelayer 122 is provided by being extended outward relative to the thirdelectrode layer 123 so that a peripheral edge of the second electrodelayer 122 surrounds a peripheral edge of the third electrode layer 123as seen in the plan view of the semiconductor chip 102. The firstelectrode layer 121 and the second electrode layer 122 are formed insidethe guard ring 112 and the third electrode layer 123 and the solderlayer 130 are formed so as to be a size smaller than the secondelectrode layer 122.

Referring to the sectional view of the emitter electrode 120 shown inFIG. 4, the thicknesses of the electrode layers and other factors do notrestrict the actual layer thickness magnitude relationship and sizeratios. The same is to be also said with respect to sectional views ofother semiconductor devices described below.

The first electrode layer 121 covers the emitter layer 106 and the gateoxide film 109 in the surface of the semiconductor chip 102. The firstelectrode layer 121 is formed of a first electroconductive materialhaving a linear expansion coefficient different from that of thesemiconductor constituting the semiconductor chip 102. In the firstembodiment, the first electroconductive material forming the firstelectrode layer 121 has AlSi as its main component. The second electrodelayer 122 is laid on the first electrode layer 121 and is formed of asecond electroconductive material. The second electroconductive materialhas a linear expansion coefficient different from that of the firstelectroconductive material and is lower in mechanical strength than thefirst electroconductive material. The third electrode layer 123 is laidon the second electrode layer 122 and is formed of a thirdelectroconductive material. The third electroconductive material has alinear expansion coefficient different from that of the firstelectroconductive material and is higher in solder wettability than thematerial of the first electrode layer 121. A typical example of a metalhaving high solder wettability is Ni. In the first embodiment, the thirdelectroconductive material is assumed to be a layer of a material havingNi as its main component, i.e., a layer of pure Ni or a Ni alloy.

The mechanical strength of the first electroconductive materialconstituting the first electrode layer 121 is referred to as “strengthSt1” for convenience sake; the mechanical strength of the secondelectroconductive material constituting the second electrode layer 122,as “strength St2”; the mechanical strength of the thirdelectroconductive material constituting the third electrode layer 123,as “strength St3”; and the mechanical strength of the solder materialconstituting the solder layer 130, as “strength St4”. In the firstembodiment, a selection of electroconductive materials for the layers ismade such that a relationship: St1>St2 is established. A selection ofmaterials may alternatively be made such that at least a relationship:St1>St2>St3 is established. Also, a selection of materials mayalternatively be made such that a relationship: St1>St3>St2 isestablished. Further, the mechanical strengths of the layers may be setso that a relationship: St1, St3, St4>St2 is established, that is, thestrength St2 is the smallest of the strengths St1 to St4. The provisionof the second electrode layer 122 lower in mechanical strength ensuresthat in the event of occurrence of a thermal shock, the thermal shock isconcentrated in the second electrode layer 122. The second electrodelayer 122 bears the shock. Therefore, even when a crack occurs, it canbe stopped by the second electrode layer 122. Thus, the growth of acrack into the IGBT cell region in the layers below the first electrodelayer 121 can be prevented. Also, the first electrode layer 121 can beprotected from cracking.

Description will be made of “mechanical strength”. In comparison betweendifferent two materials, basically one of the materials higher intensile strength (N/mm²) is considered to be higher in mechanicalstrength. In a case where two materials are equivalent in tensilestrength but differ in another numeric value (proof stress or hardness),hardness or proof stress (N/mm²) may then be used as an index. There arevarious hardness tests, for example, for Brinell hardness, Vickershardness, Rockwell hardness and Shore hardness. In any case, valuesmeasured by the same test may be compared to determine the magnituderelationship. Proof stresses of materials may be determined bycomparing, for example, numeric values representing 0.2% proof stressesof the materials. In a case where a plurality of materials areequivalent in tensile strength, one of the materials having a hardnesshigher than that of another of the materials is considered to be higherin mechanical strength. Further, in a case where a plurality ofmaterials are equivalent in tensile strength and in hardness, one of thematerials having a proof stress higher than that of another of thematerials is considered to be higher in mechanical strength. Thus, amagnitude relationship in terms of mechanical strength can be determinedin priority order: tensile strength>hardness>proof stress. Typicalnumeric values of mechanical strengths of metallic materials measured inbulk have been made public. Comparison between mechanical strengths ofmaterials may be made by referring to the bulk strength values madepublic.

A further concrete description will be made on the basis of theabove-described magnitude relationship in terms of “mechanicalstrength”. The first electroconductive material may be AlSi. When thefirst electroconductive material is AlSi, the second electroconductivematerial may be pure aluminum or an aluminum alloy lower in mechanicalstrength than the first electroconductive material. Further, the firstelectroconductive material may be AlSi having a proportion of Si higherthan 1%. That is, the material of the first electrode layer 121 is AlSiin which the proportion of Si added to Al is higher than 1%. As aresult, breakdown of the device due to a crack caused by a thermal shockcan be prevented and an effect of improving the reliability byincreasing the proof stress of the first electrode layer 121 isobtained. AlSi in which the proportion of Si is in a specific numericvalue range of, for example, 1 to 2% may be used. A modification may bemade such that the first electroconductive material is AlSiCu in whichthe proportion of Si is higher than 1%, and which contains Cu. When thefirst electroconductive material is AlSiCu, the second electroconductivematerial may be pure aluminum or an aluminum alloy. AlSiCu in which theproportion of Si is in a specific numeric value range of, for example, 1to 2% may be used. As a result, breakdown of the device due to a crackcaused by a thermal shock can be prevented and an effect of improvingthe reliability by increasing the proof stress of the first electrodelayer 121 is obtained. As pure aluminum to be used as the secondelectroconductive material, any of various materials having an Alcontent of 99% or higher may be used and high-purity aluminum having anAl content of 99.9% or higher may be used. Another modification may bemade in which each of the first electroconductive material and thesecond electroconductive material is AlSi and each of the firstelectrode layer 121 and the second electrode layer 122 is constructed bystacking a plurality of AlSi layers. In such a case, the mechanicalstrength of the second electrode layer 122 can be reduced in comparisonwith that of the first electrode layer 121 by setting the proportion ofSi in the second electroconductive material lower that in the firstelectroconductive material.

The semiconductor device 100 capable of preventing breakdown of thedevice when a thermal shock occurs and having an extended lifetime andimproved reliability can be provided. Even if the power semiconductormodule 10 is used under a thermally severer condition, e.g., ahigh-temperature operating condition, improved reliability of the modulecan be ensured thanks to the incorporation of the semiconductor device100.

FIG. 5 is a schematic plan view of the other semiconductor device 150according to the first embodiment of the present invention. FIG. 6 is aschematic sectional view of the semiconductor device 150. Thesemiconductor device 150 is a diode comprising a semiconductor chip 152of a construction different from that in the semiconductor device 100shown in FIGS. 3 and 4. The semiconductor device 150 includes thesemiconductor chip 152, a cathode electrode 156 and an anode electrode151. The anode electrode 151 has the same shape and multilayer structureas those of the emitter electrode 120, and the cathode electrode 156 hasthe same shape and material as those of the collector electrode 140. Thesemiconductor chip 152 includes a drift layer 155 formed of an n⁻-typeSiC, an anode layer 154 which is a p⁺ layer provided in a surface of thedrift layer 155, and a cathode layer 153 which is an n⁺ layer providedon a back surface of the drift layer 155. A guard ring 112 and a channelstopper 113 are provided around the anode layer 154, as are those in thesemiconductor device 100. The anode electrode 151 is laid on the anodelayer 154. The anode electrode 151 has a first electrode layer 121, asecond electrode layer 122 and a third electrode layer 123 laid one onanother in this order, as does the emitter electrode 120. The anodeelectrode 151 is assigned the reference numeral different from that forthe emitter electrode 120 for distinction from the same.

FIG. 7 is a schematic sectional view of a semiconductor device 160according to a modified example of the first embodiment of the presentinvention. The semiconductor device 160 has the same construction as thesemiconductor device 100 except that the emitter electrode 120 isreplaced with an emitter electrode 161. The emitter electrode 161 has abarrier metal layer 124 inserted in the emitter electrode 120. Thebarrier metal layer 124 is inserted between the first electrode layer121 and the second electrode layer 122 and is formed of anelectroconductive material at least higher in mechanical strength thanthe second electroconductive material. More specifically, the materialof the barrier metal layer 124 is titanium (Ti) or a Ti alloy. Amaterial having a high mechanical strength is used for the barrier metallayer 124 in order to prevent a crack generated in the second electrodelayer 122 from growing into the first electrode layer 121. Thus, withfunctioning of the barrier metal layer 124 as a barrier metal, a crackgenerated in the second electrode layer 122 is prevented from growinginto the first electrode layer 121 and the IGBT cell region below thefirst electrode layer 121.

FIG. 8 is a schematic sectional view of a semiconductor device 180according to another modified example of the first embodiment of thepresent invention. The semiconductor device 180 has the sameconstruction as the semiconductor device 150 except that the anodeelectrode 151 is replaced with an anode electrode 181. The anodeelectrode 181 has a barrier metal layer 124 inserted between the firstelectrode layer 121 and the second electrode layer 122 in the anodeelectrode 151.

An example of a method of manufacturing the semiconductor device 100 andthe power semiconductor module 10 will be described. In this example,the electrodes are formed by using sputtering. First, the semiconductorchip 102 formed by processing including well layer forming by impurityimplantation, trench forming, and trench gate forming by embedding gateinsulating film and polysilicon is prepared. The semiconductor chip 102is placed in a chamber of a sputtering apparatus and the emitterelectrode 120 is formed by sputtering using desired film forming metalmaterials as targets. For example, a target formed of AlSi is used forfilm forming of the first electrode layer 121; a target formed of purealuminum, for film forming of the second electrode layer 122; and atarget formed of Ni, for film forming of the third electrode layer 123.These targets may be prepared and used by being interchanged. If thematerial and composition of each electrode layer are changed, thetargets may be changed. Also, in a method of manufacturing thesemiconductor device 150, the semiconductor chip 152 is prepared and theanode electrode 151 may be formed by sputtering. In the case of themodified examples shown in FIGS. 7 and 8, a Ti target for example, isfurther prepared for the barrier metal layer 124 and sputtering may beperformed by using this target between the step of forming the firstelectrode layer 121 and the step of forming the second electrode layer122. Manufacturing methods for the gate electrode pad 142, the collectorelectrode 140 and the cathode electrode 156 are not particularlyspecified. However, each of these electrodes may also be formed bysputtering. After the electrodes are formed, the semiconductor devices100 and 150 are mounted on the heat radiating plate 20 by means ofsolder 30 and the junctions between the semiconductor devices 100 and150 and the lead frame 12 are made by means of the solder layer 130. Thegate electrode pad 142 on the semiconductor device 100 and the leadframe 14 are connected by wires 16, and the devices are covered with themolding resin 40.

In the first embodiment, the area wetted with solder is restricted byforming the third electrode layer 123 so that the third electrode layer123 is a size smaller than the second electrode layer 122 in order toavoid shorting between the guard ring 112 and the emitter electrode 120as a result of spreading of solder in a wetting manner. When the leadframe 12 is joined by solder, stress can concentrate more easily in theemitter electrode 120 on the front surface side than in the collectorelectrode 140 on the back surface side. Therefore, cracking due to athermal shock tends to be more considerable in the front electrode thanin the back electrode. In this respect, however, the second electrodelayer 122 is provided to cope with cracking in the first embodiment.

Second Embodiment

A power semiconductor module according to a second embodiment of thepresent invention has the same shape and structure as the powersemiconductor module 10 according to the first embodiment except thatthe semiconductor devices 100 and 150 are respectively replaced withsemiconductor devices 200 and 250. In the following description,therefore, components identical or corresponding to those in the firstembodiment are described while being assigned the same referencenumerals. Also, the description will be made mainly of points ofdifference from the first embodiment, and the description of commonmatters is simplified or omitted.

FIG. 9 is a schematic plan view of a semiconductor device 200 accordingto the second embodiment of the present invention. FIG. 10 is aschematic sectional view of the semiconductor device 200. FIG. 10 showsa section of the semiconductor device 200 taken along line C-C in FIG.9. The semiconductor device 200 according to the second embodiment hasthe same construction as the semiconductor device 100 according to thefirst embodiment except that the emitter electrode 120 is replaced withan emitter electrode 220. In the following description, therefore,components identical or corresponding to those in the first embodimentare described while being assigned the same reference numerals. Also,the description will be made mainly of points of difference from thefirst embodiment, and the description of common matters is simplified oromitted.

In the first embodiment, the emitter electrode 120 has the three-layerstructure including the first to third electrode layers 121 to 123, andthe AlSi, pure Al and Ni are used as the materials of these layers asdescribed above. In a case where a number of layers differing in linearexpansion coefficient from each other are stacked, stress is caused dueto the differences in thermal expansion coefficient between thematerials and a crack can occur easily. In the semiconductor device 200according to the second embodiment, therefore, the emitter electrode 220having not a three-layer structure but a two-layer structure isprovided. The emitter electrode 220 has a stack of a first electrodelayer 221 formed of AlCu and a second electrode layer 222 formed of Cu.Cu capable of being soldered is used for the second electrode layer 222on which the solder layer 130 is to be laid. The second electrode layer222 is formed so as to be a size smaller than the other electrode layersprovided below the second electrode layer 222, as is the third electrodelayer 123 in the first embodiment. Therefore, a peripheral portion ofthe first electrode layer 221 protrudes largely beyond the edge of thesolder layer 130, as shown in FIG. 9.

The mechanical strength of an electroconductive material constitutingthe first electrode layer 221 is referred to as strength St21; themechanical strength of an electroconductive material constituting thesecond electrode layer 222, as strength St22; and the mechanicalstrength of a material constituting the solder layer 130, as strengthSt4. In this case, the composition of AlCu constituting the firstelectrode layer 221 is adjusted so that at least St21>St22 is satisfied.The mechanical strength of solder is ordinarily lower than that of Cu orthe like. In many cases, therefore, a relationship: St21>St22>St4 isestablished. As a manufacturing method according to the secondembodiment, sputtering may be performed by using AlCu and Cu as targets,as is that in the first embodiment. Therefore, the description of themanufacturing method is omitted.

The material of the first electrode layer 221 may be AlCu in which theproportion of Cu is higher than 1%, and the proportion of Cu may be setin a range of, for example, 1 to 2%. The material of the first electrodelayer 221 may be AlSiCu as an alternative to AlCu. More specifically,the material of the first electrode layer 221 may be AlSiCu in which theproportion of Si is higher than 1%. Further, the proportion of Si may beset in a range of for example, 1 to 2%.

FIG. 11 is a schematic plan view of a semiconductor device 250 accordingto a modified example of the second embodiment of the present invention.FIG. 12 is a schematic sectional view of the semiconductor device 250.The semiconductor device 250 is a diode having an anode electrode 251provided in place of the anode electrode 151 in the semiconductor device150 according to the first embodiment. The anode electrode 251 has astructure having a stack of a first electrode layer 221 and a secondelectrode layer 222, as does the emitter electrode 220 described above.

In a modified example of the emitter electrode 220 and the anodeelectrode 251 in the second embodiment described above, a barrier metallayer 224 formed of a material higher in mechanical strength than thematerial of the second electrode layer 222 may be provided between thefirst electrode layer 221 and the second electrode layer 222. Thematerial of the barrier metal layer 224 may be tantalum (Ta) or a Taalloy. FIG. 13 is a schematic sectional view of a semiconductor device260 according to another modified example of the embodiment of thepresent invention. The semiconductor device 260 has the sameconstruction as the above-described semiconductor device 200 except thatan emitter electrode 261 in which a barrier metal layer 224 is insertedis provided.

In a still another modified example, each of the emitter electrode 220and the anode electrode 251 in the second embodiment may include“another electrode layer” between the first electrode layer 221 and thesecond electrode layer 222, which another electrode layer is notillustrated. As a material for the other electrode layer, a materialhaving a linear expansion coefficient different from that of thematerial of the first electrode layer 221 and lower in mechanicalstrength than the material of the first electrode layer 221 is used. Thefirst electrode layer 221 and the other electrode layer may be formed ofAlCu or AlSiCu with the same composition. In this case, the proportionof Cu contained in the material of the other electrode layer may belower than that in the first electrode layer 221. The mechanicalstrength of the other electrode layer, which is represented by St23, maybe set in this way so that a relationship: St21>St23 is established. Themechanical strength of the other electrode layer may alternatively beset so that a relationship: St21>St22>St23 is established.

In the above descriptions of the first and second embodiments, the IGBTshaving the trench gate electrode 104 and the diodes are described asexamples of implementation of the semiconductor device according to thepresent invention. However, the present invention can also be applied tosemiconductor devices other than those described above.

FIG. 14 is a schematic sectional view of a semiconductor device 300according to a further modified example of the embodiment of the presentinvention. The semiconductor device 300 is a metal-oxide-semiconductorfield-effect transistor (MOSFET). The structure of the semiconductordevice 300 as viewed in plan is the same as that according to the firstembodiment shown in FIG. 3 for example. Illustration of the structure ina plan view is therefore omitted. The difference between thesemiconductor device 300 and the semiconductor device 100 resides in adevice structure formed in a semiconductor chip 302 and the devicestructure formed in the semiconductor chip 102. The semiconductor chip302 has basically the same construction as the semiconductor chip 102except that the collector layer 111 and the charge accumulation layer107 are not included, and that a drain layer 310 is included in place ofthe buffer layer 110. After ordinary association between the elements ofan IGBT and elements of a MOSFET, the emitter layer 106, the emitterelectrode 120 and the collector electrode 140 in the IGBT aredifferently read as “source layer 106”, “source electrode 120” and“drain electrode 140” in the MOSFET. A film other than oxide film may beused as gate insulating film 105. In a case where this modification ismade, the semiconductor device 300 is called a MISFET. Further, each ofmodifications described in the descriptions of the first and secondembodiments can also be applied.

FIG. 15 is a schematic sectional view of a semiconductor device 400according to still a further modified example of the embodiment of thepresent invention. The semiconductor device 400 is a MOSFET having not atrench gate but a planar gate. The planar gate is formed of a gateinsulating film 405 and a gate electrode 404. The semiconductor device400 includes an n-type drift layer 103, an n⁺-type drain layer 411, anda drain electrode 440. As shown in FIG. 15, the semiconductor device 400includes a plurality of n⁺-type source layers 406, a plurality of p-typebody layers 408, and a plurality of source electrodes 420. Theseelements are provided on opposite sides of the planar gate. Each sourceelectrode 420 includes first to third electrode layers 121 to 123, asdoes, for example, the emitter electrode 120 in the first embodiment.The structure of the semiconductor device as viewed in plan may bethought to be the same as that according to the first embodiment shownin FIG. 3 for example. Illustration of the structure in a plan view istherefore omitted. FIG. 16 is a schematic sectional view of asemiconductor device 450 according to still a further modified exampleof the embodiment of the present invention. The semiconductor device 450has a source electrode 451 provided in place of the source electrode 420in the semiconductor device 400. The source electrode 451 has the samestructure as the emitter electrode 220 according to the secondembodiment. A conversion into a MISFET may be made by using as gateinsulating film 105 an insulating film other than oxide film. Aconversion into an IGBT can also be made by adding the collector layer111 between the drain electrode 440 and the drain layer 411 in thesemiconductor device 400. Further, each of the various modificationsdescribed in the descriptions of the first and second embodiments canalso be applied to the source electrodes 420 and 451.

FIG. 17 is a schematic sectional view of a semiconductor device 500according to still a further modified example of the embodiment of thepresent invention. The semiconductor device 500 is a thyristor. Thesemiconductor device 500 includes a p-type semiconductor layer 511formed SiC for example, an n-type semiconductor layer 512, a p-typesemiconductor layer 513 and an n-type semiconductor layer 514. An anodeelectrode 151 and a cathode electrode 156 are respectively provided on afront surface and a back surface of the stack of these semiconductorlayers. Further, a gate electrode 504 is connected to the p-typesemiconductor layer 513. The anode electrode 151 has the same structureas the anode electrode 151 in the first embodiment. As a modifiedexample of the semiconductor device 500 shown in FIG. 16, asemiconductor device 550 shown in FIG. 18 may be provided by replacingthe anode electrode 151 with the anode electrode 251 according to thesecond embodiment. Further, each of the various modifications describedin the descriptions of the first and second embodiments can also beapplied to the anode electrodes 151 and 251.

In recent years, semiconductors having a bandgap larger than that ofsilicon (Si) (wide-bandgap semiconductors) have found applications tosemiconductor devices. In the first and second embodiments and theabove-described modified examples, the semiconductor material is assumedto be SiC, which is one of wide-bandgap semiconductors. However, thepresent invention is not limited to this. A wide-bandgap semiconductorother than SiC may suffice. More specifically, a gallium nitride-basedmaterial (GaN) or diamond may suffice. A wide-bandgap semiconductordevice is capable of operating at high temperature in comparison with Sisemiconductor devices. There is, therefore, a strong possibility of awide-bandgap semiconductor device being used under a severerhigh-temperature condition. Since the need for measures to cope withcracking due to a thermal shock in a wide-bandgap semiconductor deviceis stronger than that in the case of Si semiconductor devices asdescribed above, the anti-cracking measures according to the embodimentsdescribed above are further effective in the case of using awide-bandgap semiconductor device. Needless to say, Si can be used as asemiconductor material in place of a wide-bandgap semiconductor.

In the semiconductor devices 100 to 500 according to the above-describedembodiments and the modified examples of the embodiments, the conductiontype opposite to that described above by way of example can also beadopted for each layer. Also, the same structures as those of theemitter electrodes 120 and 220, the anode electrodes 151 and 251 and themodified examples of these may be applied to the collector electrode 140and the cathode electrode 156. In the power semiconductor modules 10according to the first and second embodiments described above, theemitter electrodes 120 and 220 of the semiconductor devices 100 and 200which are IGBTs, and the anode electrodes 151 and 251 of thesemiconductor devices 150 and 250 which are diodes have multilayerstructures similar to each other (that is, the layers are formed of thesame materials). However, the present invention is not limited to this.For example, a power semiconductor module 10 may be formed by combiningthe semiconductor device 100 in the first embodiment and thesemiconductor device 250 in the second embodiment; a power semiconductormodule 10 may be formed by combining the semiconductor device 200 in thesecond embodiment and the semiconductor device 150 in the firstembodiment; and a plurality of semiconductor devices provided in thepower semiconductor module 10 may use electrode materials different fromeach other.

The features and advantages of the present invention may be summarizedas follows.

In the semiconductor device according to the first aspect, theoccurrence of cracking in the first electrode layer when a thermalstress occurs can be reduced by laying on the first electrode layer thesecond electrode layer formed of a material lower in mechanicalstrength, thereby inhibiting transmission of cracking into thesemiconductor layer through the first electrode layer.

In the semiconductor device according to the second aspect, theoccurrence of cracking in the first electrode layer when a thermalstress occurs can be reduced by providing on the semiconductor layer thesecond electrode layer formed of a material lower in mechanicalstrength, thereby inhibiting transmission of cracking into thesemiconductor layer through the first electrode layer.

Obviously many modifications and variations of the embodiments arepossible in the light of the above teachings. It is therefore to beunderstood that within the scope of the appended claims the inventionmay be practiced otherwise than as specifically described. The entiredisclosure of Japanese Patent Application No. 2015-125832, filed on Jun.23, 2015 including specification, claims, drawings and summary, on whichthe Convention priority of the present application is based, isincorporated herein by reference in its entirety.

What is claimed is:
 1. A semiconductor device comprising: a collector,cathode, or drain electrode formed on a back surface of a semiconductorchip; a semiconductor layer including an n-type drift layer and at leastone n-type source layer formed on a front surface of the semiconductorchip; and a first electrode, formed on the front surface of thesemiconductor chip, the first electrode including: a first electrodelayer provided on the front surface of the semiconductor chip and formedof a first electroconductive material including AlSi in which theproportion of Si is higher than 1%; a second electrode layer laid on thefirst electrode layer and formed of a second electroconductive materialincluding Al, a proportion of Si in the second electrode layer beingless than the proportion of Si in the first electroconductive layer, andthe second electrode layer having a linear expansion coefficientdifferent from that of the first electroconductive material and beinglower in mechanical strength than the first electroconductive material;and a third electrode layer laid directly on the second electrode layerand formed of a third electroconductive material having a linearexpansion coefficient different from that of the first electroconductivematerial and having solder wettability higher than that of the firstelectroconductive material, wherein a guard ring is provided in thefront surface of the semiconductor layer, the guard ring surrounding thefirst electrode layer as seen in a plan view, and the second electrodelayer is provided by being extended outward relative to the thirdelectrode layer so that a peripheral edge of the second electrode layersurrounds a peripheral edge of the third electrode layer as seen in theplan view.
 2. The semiconductor device according to claim 1, furthercomprising a barrier metal layer provided between the first electrodelayer and the second electrode layer and formed of an electroconductivematerial higher in mechanical strength than the second electroconductivematerial.
 3. The semiconductor device according to claim 2, wherein theelectroconductive material of the barrier metal layer is Ti or a Tialloy.
 4. The semiconductor device according to claim 1, wherein thefirst electroconductive material is AlSi and the secondelectroconductive material is pure aluminum.
 5. The semiconductor deviceaccording to claim 4, wherein the first electroconductive material isAlSi in which the proportion of Si is higher than 1%.
 6. Thesemiconductor device according to claim 1, wherein the firstelectroconductive material is AlSiCu in which the proportion of Si ishigher than 1%, and which contains Cu.
 7. The semiconductor deviceaccording to claim 1, further comprising: a solder layer laid on thethird electrode layer; and a lead frame soldered to the third electrodelayer by means of the solder layer.
 8. The semiconductor deviceaccording to claim 1, wherein the material of the semiconductor layer isa wide-bandgap semiconductor.
 9. The semiconductor device according toclaim 1, further comprising a channel stopper provided outside the guardring.
 10. A semiconductor device comprising: a collector, cathode, ordrain electrode formed on a back surface of a semiconductor chip; asemiconductor layer including an n-type drift layer and at least onen-type source layer formed on a front surface of the semiconductor chip;and a first electrode, formed on the front surface of the semiconductorchip, the first electrode including: a first electrode layer provided onthe front surface of the semiconductor chip and formed of either AlCu inwhich the proportion of Cu is higher than 1% or AlSiCu in which theproportion of Si is higher than 1%; and a second electrode layer laid onthe first electrode layer and formed of Cu, wherein a guard ring isprovided in the front surface of the semiconductor layer, the guard ringsurrounding the first electrode layer as seen in a plan view, and thefirst electrode layer is provided by being extended outward relative toa peripheral edge of the second electrode layer as seen in the planview.
 11. The semiconductor device according to claim 10, wherein thematerial of the first electrode layer is AlCu in which the proportion ofCu is higher than 1%.
 12. The semiconductor device according to claim10, wherein the material of the first electrode layer is AlSiCu in whichthe proportion of Si is higher than 1%.
 13. The semiconductor deviceaccording to claim 10, further comprising a barrier metal layer providedbetween the first electrode layer and the second electrode layer andformed of a material higher in mechanical strength than the secondelectroconductive material.
 14. The semiconductor device according toclaim 13, wherein the material of the barrier metal layer is Ti or a Tialloy.
 15. The semiconductor device according to claim 10, furthercomprising: a solder layer laid on the second electrode layer; and alead frame soldered to the second electrode layer by means of the solderlayer.
 16. The semiconductor device according to claim 10, wherein thematerial of the semiconductor layer is a wide-bandgap semiconductor. 17.The semiconductor device according to claim 10, further comprising achannel stopper provided outside the guard ring.